Torsion spring mount for suspended ceiling panels

ABSTRACT

The present invention provides an improved frame clip arranged and constructed to be easily field-mounted and/or reconfigured on a panel frame such as those used to form suspended ceilings. By allowing the installation of the frame clips to be deferred until the panels are being installed, the frame clip permits the panels to be shipped without frame clips and/or attachment hardware, such as torsion springs, installed, thereby reducing the likelihood of shipping damage.

FIELD OF THE INVENTION

The invention is directed toward the field of suspended ceiling systems,particularly to torsion spring attachment systems, and more particularlyto a clip and frame assembly for torsion spring attachment.

BACKGROUND OF THE INVENTION

Suspended acoustical ceiling systems are frequently used to maskfunctional systems such as plumbing, electrical wiring,telecommunications wiring and the like. There are two basic types ofsuspended acoustical ceiling systems: lay-in panel systems, in which theceiling tiles are lifted into and rest on a metal grid suspension systemwith no physical attachment; and frame panel systems in which each ofthe tiles is surrounded by a rigid frame that is, in turn, connectedsecurely to a metal grid.

FIG. 1 depicts a typical suspended ceiling system 100 of the frame paneltype comprising plurality of ceiling panels 102 that are supported byand removably attached to a suspended grid 104. Torsion springs 112 areattached to each panel 102 and provide a removable means for holding thepanel securely against a foot portion 104 a of the grid 104. Asillustrated in FIG. 1, one panel, panel 102 a, is depicted in an openand partially disconnected orientation in which two of the torsionsprings 112 a have been partially disengaged from the corresponding gridclips 106, allowing the panel 102 a to be lowered relative to the grid104, and the other two torsion springs 112 have been completelydisconnected from their corresponding grid clips (not shown), allowingthe panel to be rotated away from the grid to provide access to thespace above the suspended ceiling. The torsion springs 112 are typicallyattached to the individual panels using a series of panel clips 110 (notshown) that are attached to the metal frame 108 at appropriate pointsaround the edge of the metal frame.

FIG. 2 illustrates in more detail the construction and configuration ofthe various mechanical elements in a conventional frame type panelsystem according to FIG. 1. As illustrated in FIG. 2, the support gridmay be formed from a plurality of T-bars 250, each of which may includea foot flange 253, a web 251 and a bead portion 254. Grid clips 230 maybe provided on or attached to the bead 254 using a releasable fastener,such as screw 240. As illustrated, each grid clip 230 includes aU-shaped channel 232 and an opposed pair of projecting flanges 234 inwhich a slot 236 is provided.

The arms 218 of the torsional springs 214 are arranged and configured tofit into the slot 236 and provide a frictional fit sufficient to holdthe panel 200 in place against the foot flange 253 when the panel is inthe installed position. The arms 218 of the torsional spring 214 mayalso be provided with retaining feet 220 or other structures that arearranged and configured to rest against an upper surface of theprojecting flange 234 for suspending the panel when lowered into adisengaged position below the grid. The arms 218 of the torsional spring214 may also be arranged and configured so that they may be manuallydeflected to release the engagement between the retaining feet 220 andthe projecting flange 234 and allow the panel or one side of the panelto be completely detached from the grid.

Each framed panel 200 includes a frame 226 formed around the outer edgeof the tile 228. The framed panel 200 may include an optional cover 210of fabric or other suitable materials. A frame clip 212 fits onto aflange provided on the frame 226 and provides a raised hook portion thatis configured fit through the wound portion 216 of the torsional spring214 and thereby suspend the panel from the torsional spring.

To fit the framed panel 200 against the T-bars 250, the arms 218 of thetorsion spring 214 are pushed up through the slot 236 resulting in thearms 218 spreading out in a v-shape. Consequently, the frame 226 (or thefabric 210) will bear against the foot portion 253 of the T-bar. Toassist in aligning adjacent panels, an optional alignment clip 290 canbe attached to the T-bar 250.

SUMMARY OF THE INVENTION

Exemplary embodiments of the present invention provide an improved frameclip arranged and configured to be easily field-mounted and/or easilyreconfigured on a panel frame. The ease with which the frame clip may beattached to a panel frame without contacting the panel tile allows thepanels to be shipped without frame clips and/or torsion springs, therebysimplifying the packaging and reducing the likelihood of shipping damageresulting from projecting edges.

The improved frame clip also provides a locking function for securingthe wound portion of a torsion spring or other attachment means to apanel frame as the frame clip is secured. This locking functionsimplifies panel installation and removal by ensuring that the torsionsprings are not dislodged as a result of panel movement and reducing thelikelihood that a panel will drop unexpectedly while being handled.

The improved frame clip may be attached to the panel frame using avariety of fastening means. For example, the channel wall of the panelframe may be provided with a groove or other indents centered oppositethe channel opening to aid in the attachment of the frame clip usingself-drilling fasteners. Similarly, the receiving portion of the panelframe can be provided with holes for self-tapping fasteners or maycontain a nut or other element for receiving the forward portion of afastener. The panel frame may also be provided with notches, detents orother positioning indicia to improve the ability of an installer toposition the frame clip accurately and repeatedly.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are intended to depict exemplary embodimentsof the invention to aid those of ordinary skill in the art inunderstanding the present invention and should not be interpreted insuch as manner as to limit the scope of the present invention to theillustrated embodiments. Similarly, the accompanying drawings are not,unless explicitly noted, drawn to scale and should not be interpreted ina manner that limits the size, spacing or relative dimensions of theillustrated mechanical elements.

FIG. 1 is a three-quarter perspective drawing of a conventionalsuspended ceiling system utilizing torsion spring attachments;

FIG. 2 is a more detailed view of a conventional torsion springattachment system suitable for use in the suspended ceiling systemillustrated in FIG. 1;

FIGS. 3A-C are plan, side and front views of a frame clip according toan exemplary embodiment of the present invention;

FIG. 4 provides a three-quarter view of a panel frame according to anexemplary embodiment of the invention;

FIGS. 5A-D are a sequence of views illustrating the insertion andmounting of a frame clip as illustrated in FIGS. 3A-C into acorresponding panel frame according generally to FIG. 4;

FIGS. 6A-C are views illustrating exemplary embodiments of frame clipsutilizing various exemplary hook configurations;

FIGS. 7A-C are views illustrating exemplary combinations of frame clipinserts and corresponding panel frame channel configurations;

FIG. 8 illustrates the mechanical relationship of certain structuralelements of a frame clip according generally to FIG. 3A when installedin a panel frame generally according to FIG. 4 to form an exemplaryembodiment of the present invention;

FIG. 9 illustrates a range of motion for a captive torsion springattached to a panel frame using a frame clip according to an exemplaryembodiment of the invention;

FIGS. 10A and 10B provide a plan view of the action of a parallelogramnut suitable for use in combination with a frame clip and frameaccording to exemplary embodiments of the present invention; and

FIGS. 11A and 11B provide a side view of a parallelogram nut accordingto FIGS. 10A and 10B being used in combination with an exemplary frameclip, frame and fastener in accord with the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

As illustrated in FIGS. 3A-C, an exemplary frame clip 10 according tothe present invention includes a main body 12 that includes a topsurface 14, a bottom surface 16, a first length 18 and a first width 20and is generally planar. The frame clip 10 also includes an insert 22that has an upper surface 24, a lower surface 26, a second length 28 anda second width 30 and, like the main body, is generally planar but isoffset from the main body 12 by an offset depth 32 and an offset length34. The frame clip 10 also includes a neck 36 that connects the mainbody 12 and the insert 22 and maintains their relative parallel andspaced apart orientation. The frame clip 10 also defines a longitudinalaxis and may be generally symmetrical about the axis.

The frame clip 10 also includes a hook 38 extending above the main body12 that includes a free forward portion 40 and is attached to the mainbody of the frame clip at a rear portion 42. The hook 38 is typicallyoriented in a plane generally perpendicular to both the plane defined bythe main body 12 and the longitudinal axis of the frame clip 10, butdepending on the particular application, other orientations may beutilized. The forward portion 40 of the hook may extend downwardly to apoint generally adjacent a plane defined by the bottom surface 16 of themain body 12 or by an upper surface of a frame to which the frame clipis attached.

The forward portion 40 of the hook 38 is also set apart from the mainbody by a distance sufficient to allow the wound portion 44 of a torsionspring 46 to be placed on the hook without interference from the mainbody 12. Depending on the location of the forward portion 40 of the hook38, a notch or recess 48 may be provided at a corresponding edge in themain body 12 of the frame clip 10 to ensure sufficient spacing isavailable. The frame clip 10 may also include one or more openings 65arranged on one or both sides of the hook 38 through which a fastenermay be inserted to secure the frame clip to a panel frame.

As illustrated in FIG. 4, the frame clip 10 is arranged and configuredto be used with a corresponding frame 52. The frame 52 may beconstructed of a metal, such as aluminum or an alloy, or a polymericmaterial that may include reinforcing materials. The frame may be formedby extrusion, pultrusion, machining or casting depending on thematerial(s) used and the intended application, but a conventionalaluminum extrusion will generally be satisfactory. The frame 52 includesa channel 54 into which the insert 22 will fit, the channel having aninner periphery, inner shoulder surfaces 56, outer shoulder surfaces 58,a rear wall 60, a longitudinal opening 62 and a longitudinal channelaxis. The frame 52 may also include a groove, notch or other structureson the rear wall 60 of the channel 52 to improve the ease with whichself-tapping or self-drilling fasteners may be inserted into the rearwall. The frame 52 will also typically be provided with another channel,slot or projections 68 arranged and configured to receive and support aceiling tile or similar object within a completed panel frame.

FIGS. 5A-D illustrate a method of attaching a frame clip 10 to acorresponding frame 52. As illustrated in FIG. 5A, the thickness of theframe clip 10 is smaller than the opening 62 into the channel 54provided in the frame 52, thereby allowing the frame clip to beappropriately oriented with the insert 22 positioned in the channel. Asillustrated in FIG. 5B, the frame clip 10 can then be rotated generallyabout a longitudinal axis so that the insert 22, which is preferablyconfigured to have an outer periphery generally corresponding to, butslightly smaller than, at least portions of the inner periphery of thechannel 54 will be held in the channel. Similarly, the neck 36 of theframe clip 10 is typically configured to have a maximum width slightlysmaller than the width of opening 62 so that the frame clip can berotated without binding on the sides of the opening. As illustrated inFIG. 5B, the insert 22 is configured to be wider than the opening 62into the channel so that when the plane of the frame clip 10 issubstantially perpendicular to the longitudinal channel axis, attemptingto remove the frame clip from the channel causes the insert to contactthe inner shoulder surfaces 56 of the frame 52 and thereby tend toretain the insert within the channel.

As illustrated in FIG. 5C, a torsion spring 46 can then be slipped overthe free forward portion 40 of the hook 38 provided on the frame clip10. As illustrated in FIG. 5D, the frame clip 10 can then be rotatedabout a transverse axis positioned near or extending through the neck 36portion. The repositioning of the frame clip 10 typically establishescontact between the bottom surface 16 of the main body 12 and the outershoulder surfaces 58 of the frame 52 as well as between the uppersurface of the insert 24 and the inner shoulder surfaces. The forwardportion 40 of the hook 38 will also be moved adjacent a portion of theframe 52 to secure the torsion spring on the hook 38 as the frame clipis rotated to its installed position. Once the frame clip 10 isappropriately positioned, a fastener such as a screw 64 can be attachedto the frame through a portion of the frame clip. One or more holes 65or thinned portions may be provided in the main body 12 of the frameclip to assist in the insertion of an appropriate fastener.

As illustrated in the FIGS. 6A-C, the hook 38 may be positioned in anumber of orientations relative to the main body 12 of the frame clip10. A preferred embodiment is illustrated in FIG. 6A in which the hook38 is provided generally within the periphery of the main body 12 with anotch or recess being provided in the main body to ensure sufficientclearance to allow a torsion spring or other structure to be placed onthe hook. As illustrated in FIGS. 6B and 6C, however, the forwardportion 40 of the hook 38 can be extended well away from the main body12, provided there is other structure, such as a portion of the frame 52that can interact with the forward portion of the hook to close theopening or at least decrease the width of the opening sufficiently toprevent a structure on the hook from being removed from the hook whilethe frame clip 10 is in its fully installed position.

As illustrated in FIGS. 7A-C, both the channel 54 provided in the frame52 and the insert 22 of the frame clip 10 can assume a wide range ofconfigurations. Further, although, as illustrated, the outer peripheryof insert 22 and the inner periphery of the channel 54 are similar,those of ordinary skill in the art will appreciate that a wide range ofshapes may be used successfully. Each of the range of configurationswill, however, include an insert that is wider than the opening 62 andwill contact the inner shoulder surfaces 56 of the channel if an attemptis made to remove the frame clip 10 without first rotating the frameclip to a position in which the upper surface of the insert is generallyaligned with the longitudinal channel axis.

As illustrated in FIG. 8, when installed the frame clip 10 will bepositioned securely on the frame 52 to hold a torsion spring 46 or otherconnecting apparatus that will allow the panel, including a supportedtile 70, to be attached to a suspended grid. Typically a series of frameclips 10 will be located on the frame 52 with four or more sections offrame used to encompass and/or support the edges of a tile 70, panel orother structural element. The use of frame clips 10 according to thepresent invention located along the sides of the frame sections allowsthe corners of the frames to be reinforced more strongly and may reduceor eliminate the need for gussets or other external reinforcingstructures. This allows the basic panel frames to be assembled andshipped in a manner that reduces the likelihood of damage resulting fromprotruding structures and allows the installers to quickly install andposition the necessary frame clips and supporting structures in thefield.

As illustrated in FIGS. 10A-B, a preferred means of attaching anexemplary frame clip to the frame utilizes a nut 72 arranged andconfigured to allow insertion of the nut into the channel 54 through theopening 62 in one orientation and, by rotating the nut within thechannel, to hold the nut within the channel and stop its rotation sothat a fastener, such as a screw, can be tightened against the nut. Asillustrated in FIGS. 11A-B, the use of such a nut 72, allows thecombination of a frame clip 10, fastener 64 and nut 72 sub-assembly 74.With the nut 72 oriented appropriately, the sub-assembly 74 can then beinserted into the channel 54 as generally illustrated in FIGS. 5A-D.Once the sub-assembly 74 is in place on the frame 52, rotating thefastener 64 will cause the nut 72 to rotate and lock into the channel 54and additional rotation of the fastener will cause the nut and the frameclip 10 to be securely attached to the shoulder portions of the channel.Although the illustrated nut 72 has a generally parallelogram shape,other configurations that allow the insertion of the nut through thechannel opening and will contact the periphery of the channel whenrotated to provide a “locking” function may be used in this manner. Aself tapping screw may be used to secure the clip 10 to frame 52 withoutthe use of nut 72.

The dimensions of the frame clip 10 may also be adjusted to provide anoffset depth 32 that is slightly smaller than the thickness of theshoulder portions of the channel 54. When the offset depth 32 isadjusted in this manner, some deformation of the main body 12, insert 22and/or of the neck 36 will occur as the frame clip 10 is being fastenedto the frame 52 and provide a “locking” effect that will assist inmaintaining the position of the frame clip as the fastener is rotatedinto a fully seated position. Similarly, the upper surface 24 of theinsert 22 and/or the lower surface 16 of the main body 12 may beprovided with projections or tabs that are configured to mate withcorresponding detents or recesses in the frame 52 to help maintain theposition of the frame clip 10 relative to the frame while the fastener64 is being inserted and seated.

Those of ordinary skill in the art will appreciate that the presentinvention may be embodied in forms other than those specificallyillustrated and described herein departing from the spirit and essentialcharacteristics of the invention. The exemplary embodiments of theinvention described in detail above and illustrated in the accompanyingfigures are intended to aid in the understanding of the invention butshould not be interpreted as unduly limiting the scope of the inventionas defined in the appended claims. All changes which come within themeaning and equivalency of the claims are to be embraced.

1. A frame clip comprising: a main body, the main body having a topsurface, a bottom surface, a first length and a first width, wherein themain body generally defines a first plane that is substantially parallelto the top surface; an insert having a upper surface, a lower surface, asecond length and a second width, wherein the insert defines a secondplane parallel to the upper surface, the second plane also beingparallel to and spaced apart from the first plane; a neck, the neckconnecting a forward portion of the main body to a rear portion of theinsert, the neck having a third length and a third width, the neckgenerally defining a third plane that is inclined with respect to thefirst plane; and a hook having a forward portion and a rear portion, therear portion of the hook being attached to the main body and the forwardportion terminating in the vicinity of the first plane, wherein the hookextends above and in a generally perpendicular orientation relative tothe first plane.
 2. A frame clip according to claim 1, furthercomprising: an opening provided in the main body, the opening beinglocated in a rearward portion of the main body.
 3. A frame clipaccording to claim 2, wherein: the opening is generally centered along alongitudinal axis of the main body.
 4. A frame clip according to claim3, wherein: the opening is centered about a midpoint of the width of themain body.
 5. A frame clip according to claim 1, further comprising: arecess, the recess located along one edge of the main body adjacent theforward portion of the hook, the recess providing a minimum separationdistance between the forward portion of the hook and the main body.
 6. Aframe clip according to claim 5, wherein: the recess has a generallyarcuate profile.
 7. A frame clip according to claim 5, wherein: therecess has a depth that is less than one half the width of the mainbody.
 8. A frame clip according to claim 7, wherein: the recess has adepth that is less than one third the width of the main body.
 9. A panelassembly comprising: a frame clip including a main body, the main bodyhaving a top surface, a bottom surface, a first length and a firstwidth, wherein the main body generally defines a first plane that issubstantially parallel to the top surface; an insert having a uppersurface, a lower surface, a second length and a second width, whereinthe insert defines a second plane parallel to the upper surface, thesecond plane also being parallel to and spaced apart from the firstplane; a neck, the neck connecting a forward portion of the main body toa rear portion of the insert, the neck having a third length and a thirdwidth, the third width being less than the first and second widths, theneck generally defining a third plane that is inclined with respect tothe first plane; and a hook having a forward portion and a rear portionwith the rear portion of the hook being attached to the main body andthe forward portion terminating in the vicinity of the first plane,wherein the hook extends above and in a generally perpendicularorientation relative to the first plane; a frame including a channel,the channel having an inner periphery, inner shoulder surfaces, outershoulder surfaces, a rear wall, a longitudinal opening and alongitudinal channel axis, the open channel being arranged andconfigured to receive the frame clip insert, an outer periphery of theframe clip insert generally corresponding to the inner periphery of theopen channel when the second plane is generally perpendicular to achannel axis.
 10. A panel assembly according to claim 9, furthercomprising: a groove, the groove being provided on the rear wall of thechannel and generally centered below the longitudinal opening.
 11. Apanel assembly according to claim 9, wherein: the insert is positionedwithin the channel and the frame clip is rotated about an axis to adegree sufficient bring a portion of the upper surface of the insert incontact with the inner shoulder surfaces of the channel and bring aportion of the lower surface of the main body in contact with the outershoulder surfaces of the channel.
 12. A panel assembly according toclaim 11, further comprising: a fastener extending through the main bodyof the frame clip to fix the position of the frame clip relative to thechannel.
 13. A panel assembly according to claim 12, wherein: a forwardportion of the fastener extends into the rear wall of the channel.
 14. Apanel assembly according to claim 12, further comprising: a torsionspring having a wound body and extended legs, wherein the hook passesthrough the wound body.
 15. A panel assembly according to claim 14,wherein: the forward portion of the hook is positioned closely adjacentto or in contact with one of the outer shoulder surfaces.
 16. A methodof manufacturing a panel assembly according to claim 14 comprising:placing the insert through the longitudinal opening and into thechannel; rotating the frame clip generally about the longitudinal axisof the main body so that the insert is retained within the channel bythe inner shoulder surfaces; placing the wound body of the torsionspring on the hook; rotating the frame clip to align the longitudinalaxis of the main body with the longitudinal channel axis in a generallyparallel orientation; fastening the frame clip to the frame, whereby theforward end of the hook cooperates with one of the outer shouldersurfaces to define a substantially enclosed space.
 17. A method ofmanufacturing a panel assembly according to claim 14 wherein: fasteningthe frame clip to the frame includes passing a fastener through afastener opening provided in the main body of the frame clip and intothe channel.
 18. A method of manufacturing a panel assembly according toclaim 17, wherein: the fastener extends though the back wall of thechannel.
 19. A method of manufacturing a panel assembly according toclaim 18, wherein: the fastener is a self-drilling screw.
 20. A methodof manufacturing a panel assembly according to claim 17, wherein: thefastener extends into and cooperates with a nut provided in the channelto fasten the frame clip to the frame.
 21. A method of manufacturing apanel assembly according to claim 20, wherein: the nut is arranged andconfigured to be inserted through the longitudinal opening in a firstposition and retained within the channel in a second position, whereinrotation of the nut within the channel is limited to no more than about180°.
 22. A suspended panel frame system comprising: a plurality ofpanel assemblies according to claim 14; a grid arranged and configuredto receive the plurality of panel assemblies, the grid including gridclips arranged and configured to receive the extended legs of aplurality of torsion spring, the grid clips and the extended legscooperating to provide a removable friction fit sufficient to maintainthe panel assemblies in contact with corresponding grid surfaces.